Refrigerating machine

ABSTRACT

A refrigerating machine having a compressor driven by a motor. The motor incorporates an armature with an iron core having a cage type conductor and a permanent magnet which is magnetized so as to enable the motor to operate as a synchronous motor. A bypass passage is provided between a discharge side of the compressor and a suction side of the compressor, a shut-off valve is provided for opening and closing the bypass passage, a pressure detecting device is provided for detecting a discharge pressure from the compressor and a current detector is provided for detecting a value of drive current for the compressor. The shut-off valve is opened and closed in accordance with the discharge pressure and the value of the drive current.

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation of U.S. application Ser. No. 10/614,018, filedJul. 8, 2003 now U.S. Pat. No. 6,832,488, the subject matter of which isincorporated by reference herein.

BACKGROUND OF THE INVENTION

The present invention relates to a refrigerating machine such as arefrigerator or an air-conditioner, using a vapor compressionrefrigerating cycle.

These years, due to a tendency of increase demands of prevention ofearth warming and reduction in running cost, energy saving as torefrigerators and air-conditioners which causes energy consumption in alarge part in tenants and buildings has been promoted. In order toenhance the efficiency of a refrigerating machine such as anair-conditioner or a refrigerator and to lower the costs thereof, asdisclosed in JP-A-2001-227778, it has been known to use a built-inmagnet synchronous motor for driving a compressor, having an armatureincorporating a squirrel cage conductor and a permanent magnet so thatthe motor serves not only as an induction motor but also a synchronousmotor.

In the above-mentioned conventional technology, of a plurality ofcompressors used in a refrigerating machine, the one compressor which isa variable speed compressor driven by a built-in magnet synchronousmotor, is adapted to be subjected to an inverter drive, but the otherone or more compressors which are constant speed compressors are drivenby a commercial power source. However, although the compressor subjectedto an inverter drive is driven with a relatively high degree ofefficiency in the above-mentioned configuration, it has been not yetknown in detail how to enhance the overall efficiency of therefrigerating machine.

In the case of synchronous operation of the built-in magnet synchronousmotor, overload operation causes the built-in magnet synchronous motorto produce an insufficient torque which deteriorates the synchronousoperation so that the armature stalls, result in running of abnormalcurrent therethrough, and accordingly, there would cause a risk ofoccurrence of a dielectric breakdown of the armature windings.

BRIEF SUMMARY OF THE INVENTION

An object of the present invention is to provide a refrigerating machineusing a plurality of compressor and having a comparatively enhanceddegree of overall efficiency.

Further, another object of the present invention is to provide arefrigerating machine using a plurality of compressors, which has adegree of reliability that is comparatively enhanced.

To the end, according to the present invention, there is provided arefrigerating machine using a plurality of compressors driven by motorseach of which comprises an armature including an iron core having asquirrel cage conductor and a permanent magnet which is magnetized so asto allow the motor to serve as a synchronous motor, and a compressordrive circuit for selectively driving the motors at a power sourcefrequency by a commercial power and at a variable frequency by aninverter.

Further, according to the present invention, there is provided arefrigerating machine comprising a plurality of compressors driven bymotors each including an armature having an iron core incorporating apermanent magnet, at least one of the compressors is driven at avariable speed by an inverter, and the other compressors are driven bymotors each including an armature incorporating a squirrel cageconductor in addition to the permanent magnet.

Further, according to the present invention, there is provided arefrigerating machine including a plurality of compressors driven bymotors each having an armature with an iron core incorporating asquirrel cage conductor and a permanent magnet, and the respectivemotors can be driven at a power source frequency by a commercial powersource and also at a variable frequency by an inverter.

Further, in the refrigerating machine having the above-mentionedconfiguration, it is desirable to use a scroll compressor as theabove-mentioned compressor.

Further, in the refrigerating machine having the above-mentionedconfiguration, it is preferable to wind armature windings concentricallyin a stator in the motor.

Further, in the above-mentioned compressor having the above-mentionedconfiguration, it is preferable to use a scroll compressor as theabove-mentioned compressor, and to wind armature windings concentricallyin a stator of the motor.

Further, in the above-mentioned machine having the above-mentionedconfiguration, when it is determined that the inverter fails, it ispreferable to drive at least one of the plurality of compressors by acommercial power source.

Further, in the refrigerating machine having the above-mentionedconfiguration, every one of the plurality of compressors is driven by amotor including an armature having an iron core which incorporates asquirrel cage conductor and a permanent magnet that is magnetized so asto allow the motor to serve as a synchronous motor.

In the refrigerating machine having the above-mentioned configuration,the plurality of compressors have a uniform type.

Further, in the refrigerating machine having the above-mentionedconfiguration, there is provided a pressure detecting device on thedischarge side of the compressor which is therefore driven in accordancewith a value detected by the pressure detecting device.

Present invention will be hereinbelow detailed in the form of preferredembodiments with reference to the accompanying drawing in which.

Other objects, features and advantages of the invention will becomeapparent from the following description of the embodiments of theinvention taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a block diagram illustrating a refrigerating cycle in anembodiment of the present invention;

FIG. 2 is a cross-sectional view illustrating a self-start typesynchronous motor used in the embodiment shown in FIG. 1;

FIG. 3 is a sectional view illustrating a compressor used in theembodiment shown in FIG. 1;

FIG. 4 is a graph showing degrees of efficiency of various kinds ofmotor with respect to a rotational speed;

FIG. 5 is a graph showing power factors of an induction motor and aself-start type synchronous motor;

FIG. 6 is a time-chart showing rotation control of the compressors inthe embodiment shown in FIG. 1;

FIG. 7 is a flow-chart showing detune preventing control for a loss ofsynchronism of the self-start type synchronous motor in the embodimentshown in FIG. 1;

FIG. 8 is a graph showing a continuous operation zone of the self-starttype synchronous motor in the embodiment shown in FIG. 1; and

FIG. 9 is a block diagram illustrating a refrigerating cycle in anotherembodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1 which shows a refrigerating cycle of anair-conditioner having two compressors 1, 2, there are shown a variablespeed compressor 1 driven by an inverter and a constant speed compressor2 driven by a commercial power source. Each of the compressors 1, 2incorporates therein a built-in magnet synchronous motor (a self-starttype synchronous motor) having an armature provided with a squirrel cageconductor which allows the motor to serve as an induction motor, and apermanent magnet which is bipolar-magnetized so as to allow the motor toserve as a synchronous motor. Further, a four way valve 4, an outdoorheat-exchanger 5, an outdoor expansion valve 7, a receiver 8, indoorexpansion valves 9 a, 9 b, indoor heat-exchangers 10 a, 10 b and anaccumulator 12 are connected in the mentioned order by means of arefrigerant pipe line so as to constitute a refrigerating cycle.

Referring to FIG. 2 which is a detailed sectional view in a diametricaldirection of the motor incorporated in each of the compressors 1, 2,there are shown an armature 50, and a squirrel cage conductor 52provided around the outer peripheral surface of the armature 50. Withthis configuration, the armature 50 is rotated so as to allow the motorto serve as an induction motor. A permanent magnet 51 bipolar (N andS)-magnetized as shown is provided inside of the squirrel cage conductor52. Further, there are provided an armature iron core 54 and acrankshaft 55 which are arranged in the mentioned order in a radiallyinward direction and which are coupled to the drive portion of thecompressor as shown in FIG. 3.

Referring to FIG. 3 which is a cross-sectional view illustrating astructure of a compressor using a self-start type synchronous motor, thecompressor has a compression mechanism portion composed of a spiral lap114 which stands upright from an end plate 113 of a fixed scroll member112, a spiral lap 117 which stands upright from an end plate 116 of anorbiting scroll member 115, being engaged with the spiral lap 114, andwhich is revolved by the crank shaft 55 so as to carry out compressivemotion.

Of compression chambers 118 a, 118 b, . . . , defined between theorbiting scroll member 112 and the fixed scroll member 115 the one 118which is located at the diametrically outmost side decreases its volumetoward the centers of both scroll members 112, 115 for compressionduring the revolving motion, and compressed gas from the compressionchamber 118 is discharged from a discharge port 119 communicated withthe center part of the compression chamber 118.

The compressed gas discharged flows through a gas passage (which is notshown) formed in the fixed scroll member 112 and a frame 120 and thenflows into a portion below the frame 120 in a pressure container 121,and is then discharged outside of the compressor, through a dischargepipe 22 incorporated to a side wall of the pressure container 121.

Further, this compressor encloses therein a drive motor 123 within thepressure container 121. An oil sump part 124 is defined below the drivemotor 123. Oil in the oil sump part 124 is fed to sliding parts of theorbiting scroll member 115 and the crankshaft 55, a slide bearing 126and the like by way of an oil hole 125 formed in the crankshaft 55, dueto a pressure difference induced by the revolving motion.

The stator 60 is composed of a stator core 61, three slots 62 formed inthe stator core 61, and three teeth 63 separated from one another bythese slots 62. Armature windings 64 are concentrically wound on theteeth through the slots 62. In the figure, the armature windings 64include U-phase windings 64A, V-phase windings 64B and W-phase windings64C which are fed with power so as to rotate the armature.

With the above-mentioned configuration, since the stator 60 includesonly concentrically wound windings, the dimensions of coil ends can besmall-sized, and accordingly, it is possible to enhance the efficiencydue to a decrease in copper loss caused by windings, and to miniaturizethe compressor. Further, there is required only a concentrically windingmachine for manufacturing the compressor drive motor, the manufacturingcosts can be advantageously reduced. Further, (1) since a startingconductor provided in the armature is formed in a squirrel cage shape, amagnetic gap can be restrained to be minimum, and accordingly, effectivemagnetic fluxes can be ensured even during rated power operation; (2)since an induced current running through the conductor and magneticfluxes inflowing into the armature from the stator side are orthogonalto each other, a torque characteristic can be ensured; and (3) since anarmature manufacturing line (including a die-casting machine and thelike) for conventional induction motors can be used as it is, themanufacturing costs can advantageously reduced.

Further, since the coil end parts can be small-sized, a larger internalvolume can be ensured in the compressor, a sufficient space for a partfor separating refrigerant fluid in order to reduce rise-up of oil canbe ensured, and so forth, thereby it is possible to miniaturize anoutdoor unit even using a plurality of compressors.

Next, explanation will be made of the operation of the self-start typesynchronous motor.

In the case of the compressor 2 which is operated at a constant speed,when a power from a commercial power source 101 is applied to thearmature windings, a rotating magnetic field is induced so that aninduction magnetic field is applied to the squirrel cage conductor whichtherefore produce a torque. That is, the motor serves as an inductionmotor upon a start of the compressor, and then serves as a synchronousmotor since the motor is led into a magnetic field of the permanentmagnet so as to be rotated at a synchronous speed when the rotationalspeed of the compressor is gradually increased so as to approach 50 Hz(or 60 Hz) which is a frequency of the commercial power source 101. Atthis time, since no slip is caused substantially, substantially no lossis caused by a secondary current which is induced when the motor servesas an induction motor, thereby it is possible to operate the compressorwith a high degree of efficiency.

In the case of the variable speed compressor 1 which is subjected to aninverter drive, since the drive frequency is gradually increased fromthe frequency of the commercial power source 101 through theintermediary of an inverter circuit 102, and accordingly, the motor canbe simply accelerated up to its required synchronous speed in comparisonwith such a case that the motor is directly driven by the commercialpower source 101.

Referring to FIG. 4 which shows motor efficiency characteristics of aninduction motor, a permanent magnet synchronous motor and a self-starttype synchronous motor, that is, speeds v.s. motor efficiency, theefficiency of the self-start type synchronous motor is higher than thatof the induction motor, but is slightly lower than that of the permanentmagnet synchronous motor. However, since the permanent magnetsynchronous motor cannot be self-started directly by the commercialpower source, it requires an inverter circuit.

Referring to FIG. 5 which shows power factors of an induction motor anda self-start type synchronous motor, the induction motor lowers itspower factor since it requires an exciting current accompanied with aslip, but the self-start type synchronous motor can operate with a highpower factor since it does not require an exciting current when itcarries out synchronous operation, and accordingly, it can reduce apower source capacity.

Referring again to FIG. 1, a compressor drive circuit 100 includes powersource switches 103, 104 in order to supply a power from the commercialpower source 101 to the compressors 1, 2, direct thereto or by way of aninverter circuit 102, and accordingly, the compressors 1, 2 areselectively operated under a drive at the frequency of the commercialpower source 101 or under an inverter drive at a variable frequency.Thus, the compressor 2 can be operated also as a variable speedcompressor by the inverter circuit, and on the contrary, the compressor1 can be operated under a drive by the commercial power source, therebyit is possible to interchange both inverter drive and commercial powersource drive with each other.

If the inverter circuit fails, both compressors 1, 2 can be connected,direct to the commercial power source 101 by means of the power sourceswitches 103, 104, and accordingly, they serve as self-start typesynchronous motors so as to continue the refrigerating cycle, thereby itis possible to avoid unnecessary stopping.

Further, with the use of the power source switches 103, 104, byalternatively operating, at predetermined time intervals, thecompressors which are operated under an inverter drive at a highoperation frequency due to temperature control, that is, by operatingthe compressors through rotation, the use lives of a plurality ofcompressors 1, 2 are averaged, respectively, thereby it is possible toenhance the reliability.

Referring to FIG. 6 which shows an example of operation of fourcompressors through rotation, a compressor 1 which is operated under aninverter drive in accordance with an air-conditioning load is at firststarted, and then a compressor 2 which is driven at a constant speed bythe commercial power source is started. Then, the compressors 2, 3, 4are successively started at predetermined time intervals until arequired number of compressors becomes a value required by the load. Atthis time, in accordance with total operation times of the compressors 1to 4, which have respectively added up by operation time accumulatingmeans, the compressors are operated in order from the one whose pasttotal operation time is minimum.

When the air-conditioning load decreases so that the number ofcompressors operated at a constant speed is decreased, the compressorsare successively stopped from the one whose total operation time whichhas become longest is stopped, except a compressor which is operatedunder an inverter drive, and the compressor which is operated under aninverter drive is finally stopped. Thus, the use lives of thecompressors can be made to be uniformed, thereby it is possible toenhance the reliability of the overall air-conditioning machine.

Further, in order to determine the one of the compressors which is to bestarted, by generating a random number without using total operationtimes, which is any one of 1 to 4, that is, for example 2, thecompressor 2 may be at first started. In this case, the memory capacityof a microcomputer can be reduced, in comparison with such a case thatthe operation time accumulating means are used for a plurality of thecompressors, thereby it is possible to advantageously reduce the costs.Further, by using a self-start type synchronous motor for every of thecompressors including those operated under an inverter drive and thoseoperated under a commercial power source drive, the type of compressorsto be used can be unified, thereby it is possible reduce manufacturingcosts, managing costs and the like.

There would be presented a risk of a defective start due to aninsufficient torque of the motor in the case of a large differentialpressure between the discharge side and the suction side of thecompressor when the self-start type synchronous motor is started by thecommercial power source, and accordingly, a bypass passage 13 isincorporated from an oil separator 3 on the suction side of thecompressor to an accumulator 12 on the discharge side thereof, as shownin FIG. 1, and a bypass passage shut-off valve 14 is connected in thebypass passage 14. With this configuration, the bypass passage shut-offvalve 14 is opened so as to decrease the differential pressure betweenthe discharge side and the suction side of the compressor upon a start,thereby it is possible to prevent occurrence of a defective start of thecompressor.

Further, as shown in FIG. 9, instead of the bypass passage 13 asmentioned above, a bypass passage 13 a may be provided from thedischarge side of the compressor driven by the commercial power source,to the accumulator 12 or a passage 13 b may be provided from theaccumulator 12 to the receiver 8. In the case of the provision of thebypass passage 13 b, when a shut-off valve 14B connected in the bypasspassage 13 b is opened, gas is led from the top part of the receiver 8into the suction side of he compressor, and accordingly, the refrigerantat the inlet of the receiver has two phases so as to serve as two phaserefrigerant at the outlet of the heat-exchanger serving as a condenser.Thus, the condensing pressure can be lowered so as to reduce the load ofthe compressor, thereby it is possible to facilitate a start thereof.Further, if the bypass passage is incorporated in the compressor betweenthe high pressure part and the low pressure part in the compressionmechanism portion, the compressor can be advantageously small-sized.

Further, a check-valve 5 is incorporated in the passage between thedischarge side of the compressor 2 and the oil separator 3 on thedischarge side of the compressor 1, as shown in FIG. 1, and accordingly,the differential pressure between the discharge side of the compressor 1which has been started at first and which is operated under an inverterdriven, and the suction side of the compressor 2 which is driven atsecond, is prevented from increasing, thereby it is possible tofacilitate a start of the compressor 2.

Further, when the compressor 2 is stopped, a long time elapses until ahigh pressure which is held between the compressor 2 and the check valve15 is decreased to a lower value, but if the bypass passage 13 isopened, the pressure can be rapidly lowered. Thereby, it is possible toshorten the time required from a stop of the compressor 2 to a restartthereof.

Even during the synchronous operation of the self-start type synchronousmotor, insufficient torque is caused if the compressor falls in anoverload operating condition, and accordingly, there would be caused aloss of synchronism. In order to prevent occurrence a loss ofsynchronism, a pressure detecting device 16 and current detectors 105and 106 are provided on the discharge side of the compressor in order tocarry out control for preventing occurrence of a loss of synchronism.

Referring to FIG. 7 which shows a flow-chart for the control forpreventing occurrence of a loss of synchronism for a compressor. When astart signal for a compressor is received, a pressure is detected by thedischarge pressure sensor so as to determine whether the dischargepressure is not less than a predetermined value Pdset1 or not ischecked, and if it is true, the bypass passage is opened while thecompressor is not started until the discharge pressure Pd becomes notgreater than the value Pdset 1.

After the compressor is started, the following steps are carried out inaccordance with a detected value from the current detector 106 and adetected value from the pressure detecting device 16.

Referring to FIG. 8 which shows a zone where the compressor can becontinuously operated, and a zone where the compressor causes a loss ofsynchronism, in accordance with the current value I and the dischargepressure Pd of the compressor. Specifically, there is present anallowable maximum current value (Imax) in the zone in which thecompressor can be continuously operated, and below the maximum current,the allowable discharge pressure Pd is lowered as the current increases.Thus, whether or not the self-start type synchronous motor falls in thezone where the compressor is continuously operated, is successivelydetermined, depending upon whether conditions Pd<Pdset2−I*a (where a isa coefficient) and I<Imax are satisfied or not. Further, if it falls inthe zone where a loss of synchronism occurs, the bypass passage 13, 13 aor 13 b is opened in order to lower a load upon the motor. Further, ithas already fallen in the zone where a loss of synchronism occurs eventhough the bypass passage is opened, the compressor is once stopped, andcarry out retry control for a restart thereof.

In view of the configuration as sated above, since a scroll compressoris used as the compressor driven by the self-start type synchronousmotor, the inertia of the rotating part is low, and variation in loadtorque is also small, thereby it is possible to widen the zone in whichthe compressor can be continuously operated.

As stated above, according to the present invention, there can beprovided a refrigerating machine having a high degree of efficiency, anda high degree of reliability with reduced costs.

It should be further understood by those skilled in the art thatalthough the foregoing description has been made on embodiments of theinvention, the invention is not limited thereto and various changes andmodifications may be made without departing from the spirit of theinvention and the scope of the appended claims.

1. A refrigerating machine comprising a compressor driven by a motor,the motor incorporating an armature with an iron core having a cage typeconductor and a permanent magnet which is magnetized so as to enable themotor to operate as a synchronous motor, a bypass passage between adischarge side of the compressor and a suction side of the compressor, ashut-off valve for opening and closing the bypass passage, a pressuredetecting device for detecting a discharge pressure from the compressor,and a current detector for detecting a value of drive current for thecompressor, wherein the shut-off valve is opened and closed inaccordance with the discharge pressure and the value of the drivecurrent.
 2. A refrigerating machine according to claim 1, wherein thecompressor is a scroll compressor.
 3. A refrigerating machine comprisinga plurality of compressors each driven by a motor having an armaturewith an iron core incorporating a permanent magnet, and including afirst compressor driven at a variable speed by an inverter, and a secondcompressor having the armature with the iron core incorporating a cagetype conductor in addition to the permanent magnet, a bypass passagebetween an output side and an input side of the plurality ofcompressors, a shut-off valve for opening and closing the bypasspassage, a pressure detecting device for detecting a discharge pressurefrom the plurality of compressors, and a current detector for detectinga drive current for the second compressor, wherein the shut-off valve isopened and closed in accordance with the discharge pressure and thevalue of the drive current.
 4. A refrigerating machine according toclaim 3, further comprising a check valve provided in a passage betweena discharge side of the second compressor to a discharge side of thefirst compressor, wherein the first compressor is preferentiallystarted.
 5. A refrigerating machine according to claim 3, wherein theplurality of compressors are all driven by motors each having anarmature with an iron core incorporating a cage type conductor and apermanent magnet which is magnetized so as to enable the motor tooperate as a synchronous motor.
 6. A refrigerating machine comprising aplurality of compressors each driven by a motor having an armature withan iron core incorporating a cage type conductor and a permanent magnet,the motors for the compressors being capable of being driven by a sourcefrequency of a commercial power source and a variable frequency of aninverter, a pressure detecting device for detecting a discharge pressurefrom the plurality of compressors, and current detectors for detectingdrive currents of the respective compressors, wherein a differentialpressure between an inlet side and an outlet side of the plurality ofthe compressors is reduced in accordance with the discharge sidepressure and the drive currents.
 7. A refrigerating machine according toclaim 6, further comprising power source change-over switches forselectively one of supplying directly a commercial power to the motorsand through an inverter circuit, and a compressor drive circuit fordriving the respective motors by one a source frequency of thecommercial power source and a variable frequency of an inverter.